Support feature for joining of battery cell tabs

ABSTRACT

A battery assembly including a plurality of battery cells and at least one frame having a support feature formed thereon is disclosed. The support feature supports electrically conductive tabs of the battery cells and militates against damage to the battery assembly during a joining of one of the electrically conductive tabs with another one of the electrically conductive tabs of an adjacent battery cell or during a joining of the electrically conductive tabs of adjacent battery cells with a connector.

FIELD OF THE INVENTION

The present disclosure relates to a battery pack and more particularlyto a battery assembly for housing battery cells of the battery pack.

BACKGROUND OF THE INVENTION

A battery cell has been proposed as a clean, efficient andenvironmentally responsible power source for an electric device such asan electric vehicle, for example. Typically, a plurality of individualbattery cells such as lithium-ion battery cells, for example, isprovided to supply an amount of electric power sufficient to operate theelectric device. The plurality of individual battery cells must bephysically supported and protected, as well as be in electricalcommunication with each other and the electrical device. Further, it isoften desired to provide cooling to the battery cells during a chargingand a discharging thereof and venting to the battery cells to exhaustgasses, liquids, and solids that may be discharged therefrom. A batterypack including a battery assembly is typically provided to support,protect, and provide cooling to the battery cells and facilitate placingthe battery cells in electrical communication with each other and theassociated electrical device.

It is desirable to support the battery cells and militate against damagethereto during a joining of the adjacent individual battery cells witheach other or with an electrical connector. Further, it is desirable toproduce a battery assembly, wherein an ease of manufacturing the batteryassembly is maximized and a cost thereof is minimized.

SUMMARY OF THE INVENTION

In concordance and agreement with the present invention, a batteryassembly including a plurality of battery cells and at least one framehaving a support feature formed thereon, wherein the support featuresupports the battery cells and militates against damage to the batteryassembly during a joining of the battery cells, has surprisingly beendiscovered.

In one embodiment, the battery assembly comprises: a plurality ofbattery cells having a first electrically conductive tab and a secondelectrically conductive tab formed thereon; and a frame disposedadjacent the battery cells in stacked relation, the frame including asupport feature formed thereon, wherein the support feature supports oneof the tabs of at least one of the battery cells.

In another embodiment, the battery assembly comprises: a plurality ofbattery cells having a first electrically conductive tab and a secondelectrically conductive tab formed thereon, wherein each of the batterycells is rotated with respect to an adjacent battery cell; and a framedisposed adjacent the battery cells in stacked relation, the frameincluding a support feature formed thereon, wherein the support featuresupports the first electrically conductive tab of one of the batterycells and the second electrically conductive tab of the adjacent batterycell.

In another embodiment, the battery assembly comprises: a plurality ofbattery cells having a first electrically conductive tab and a secondelectrically conductive tab extending outwardly from a perimeterthereof, wherein each of the battery cells is rotated with respect to anadjacent battery cell; and a frame disposed adjacent the battery cellsin stacked relation, the frame including a support feature formedthereon, wherein the support feature supports the first electricallyconductive tab of one of the battery cells and the second electricallyconductive tab of the adjacent battery cell during a joining processthereof, and wherein the battery cells are series-interconnected.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present invention, willbecome readily apparent to those skilled in the art from the followingdetailed description, particularly when considered in the light of thedrawings described herein.

FIG. 1 is a partially exploded side perspective view of a batteryassembly according to an embodiment of the present invention;

FIG. 2 is an enlarged fragmentary rear perspective view of electricallyconductive tabs of the battery assembly illustrated in FIG. 1;

FIG. 3 is a partially exploded side perspective view of a batteryassembly according to another embodiment of the present invention; and

FIG. 4 is a fragmentary cross-sectional elevational view of a portion ofa battery assembly taken along section line 4-4 in FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description and appended drawings describe andillustrate various embodiments of the invention. The description anddrawings serve to enable one skilled in the art to make and use theinvention, and are not intended to limit the scope of the invention inany manner.

FIG. 1 shows a portion of a battery assembly 10 of a battery pack (notshown) according to an embodiment of the present invention. It isunderstood that the battery pack can be used for supplying electricpower to an associated electric device such as an electric vehicle, forexample. The battery assembly 10 includes end frames 11, a plurality ofcooling modules 12, and a plurality of series-interconnected batterycells 14 having a first electrically conductive tab 16 and a secondelectrically conductive tab 18 extending outwardly therefrom. It isunderstood that the battery cells 14 can be any battery cells as desiredsuch as lithium-ion battery cells, nickel-metal hydride battery cells,or other battery cells employing a different structure andelectrochemistry, for example.

Although the end frame 11 shown has a generally rectangular shape, it isunderstood that the end frame 11 can have any shape as desired. The endframe 11 can be formed as a unitary frame by injection molding anelectrically non-conductive material such as a nylon, polypropylene,metal, or other material having suitable physical and chemicalproperties, for example. It is understood that the end frame 11 can beformed by any suitable forming process as desired. The end frame 11includes an exterior first side (not shown) and an interior second side19. The first side may have a generally planar surface or may includeany surface features as desired. Wall sections 20 are formed on thesecond side 19 of the end frame 11. The wall sections 20 and an interiorsurface 23 form a cavity for receiving one of the battery cells 14therein. The wall sections 20 are designed to engage an outer perimeter21 of the battery cell 14 and locate the battery cell 14 in matingcontact with the interior surface 23. When the end frame 11 is placed ina stacked relation with the cooling modules 12 and the battery cells 14,the wall sections 20 of the end frame 11 abut an adjacent cooling module12. A recess 24 is formed in a peripheral edge of the end frame 11 toreceive one of the electrically conductive tabs 16, 18 of the batterycell 14 therein. As shown in FIG. 1, the recess 24 of the end frame 11receives the electrically conductive tab 16 therein.

A support feature 26 is formed adjacent the recess 24 on a first portion28 of the end frame 11. As illustrated, the support feature 26 has agenerally rectangular shape with a sloped planar surface 29. In anon-limiting example, the planar surface 29 has a length of about 55 mmand a width of about 7.69 mm. It is understood that the support feature26 can have any shape and size as desired. The support feature 26 shownis integrally formed with the end frame 11. It is understood, however,that the support feature 26 can be a separate component coupled to theend frame 11 by any suitable means. The support feature 26 may include aplurality of ribs (not shown) to provide strength and stability to thesupport feature 26.

Ears 30 are formed adjacent each corner of the end frame 11. An aperture31 is formed in each of the ears 30 to receive a tension rod 32 of acompression assembly (not shown) therein. The tension rods 32interconnect and align the end frame 11 and the cooling modules 12 toform the battery assembly 10 and the compression assembly applies acompressive force to the battery assembly 10 to hold the batteryassembly in the stacked relation. In the stacked relation, the coolingmodules 12 and the battery cells 14 are arranged in a repeatingalternating pattern. The cooling modules 12 maintain a desiredtemperature of the battery assembly 10. It is understood that thecooling modules 12 may be of the type described in commonly owned U.S.patent application Ser. No. 12/789,888 incorporated herein by referencein its entirety. Each of the cooling modules 12 is rotated substantially180 degrees with respect to a longitudinal axis A of the batteryassembly 10 from each adjacent cooling module 12.

In the embodiment shown, each of the cooling modules 12 includes a frame40 having an opening (not shown) formed through a central portionthereof. The frame 40 and the opening have a generally rectangularshape. It is understood that the frame 40 and the opening can have othershapes to accommodate a shape of the battery cell 14 such as square,circular, oval, and the like, for example. It is further understood thatthe frame 40 may have substantially the same shape as the end frame 11.The frame 40 can be formed as a unitary frame by injection molding amaterial such as a nylon, polypropylene, metal, or other material havingsuitable physical and chemical properties, for example. Ears 44 areformed adjacent each corner of the frame 40. An aperture 46 is formed ineach of the ears 44 to receive the tension rod 32 therein.

Recesses 50, 52 for receiving the electrically conductive tabs 16, 18therein are formed in peripheral edges of respective portions 54, 56 ofthe frame 40. Wall sections 60 are formed on a first side 62 of theframe 40. The wall sections 60 facilitate retention of one of thebattery cells 14 between adjacent frames 40 and alignment of the frames40 in the stacked relation. When the cooling modules 12 are placed inthe stacked relation, the wall sections 60 of the frame 40 abut a secondside 64, shown in FIG. 2, of the adjacent frame 40.

In the embodiment shown in FIG. 1, a slot 66 is formed in opposing legs68, 70 of the frame 40. The slots 66 provide fluid communication throughthe legs 68, 70 with a cooling assembly 72 disposed in the opening ofthe frame 40. The cooling assembly 72, shown in FIG. 2, includes aseparator plate 74 interposed between a first thermally conductive plate76 and a second thermally conductive plate 78. As illustrated, theseparator plate 74 has a substantially corrugated shape. It isunderstood, however, that the separator plate 74 can have any shape asdesired. In a non-limiting example, the entire cooling assembly 72 isdisposed in the opening of the frame 40. In another non-limitingexample, the thermally conductive plates 76, 78 are affixed to therespective sides 62, 64 of the frame 40 to seal the opening of the frameand retain the separator plate 74 therein. It should also be understoodthat the thermally conductive plates 76, 78 can be integrally formedwith the frame 40 by forming the frame 40 around the plates 76, 78employing an injection molding process, for example. The separator plate74 and the thermally conductive plates 76, 78 form a plurality of fluidflow channels 80 through an interior of the cooling assembly 72. Theflow channels 80 extend between opposing edges of the cooling assembly72 and are in fluid communication with the slots 66 formed in the legs68, 70 of the frame 40.

A support feature 82 is formed on the portion 54 of the frame 40adjacent the recess 50. In the embodiment shown, the support feature 82has a generally rectangular shape with a sloped planar surface 86. In anon-limiting example, the planar surface 86 has a length of about 55 mmand a width of about 7.69 mm. It is understood that the support feature82 can have any shape and size as desired. The support feature 82 shownis integrally formed with the frame 40. It is understood, however, thatthe support feature 82 can be a separate component coupled to the frame40 by any suitable means. The support feature 82 may include a pluralityof ribs 88 to provide strength and stability to the support feature 82as shown in FIG. 2.

In the embodiment shown in FIG. 1, the electrically conductive tabs 16,18 extend outwardly from the perimeter 21 of the battery cell 14. It isunderstood that the electrically conductive tabs 16, 18 may extendoutwardly from the battery cell 14 from any location along the perimeter21 thereof as desired. In the embodiment shown, the first electricallyconductive tab 16 is formed from an aluminum material, an aluminum cladmaterial, or an aluminum plated material. The second electricallyconductive tab 18 is formed from a copper material, a copper cladmaterial, or a copper plated material. The first electrically conductivetab 16 and the second electrically conductive tab 18 extend outwardlyfrom between two adjacent cooling modules 12 or from between the endframe 11 and an adjacent cooling module 12. Each of the battery cells 14is rotated substantially 180 degrees with respect to the longitudinalaxis A of the battery assembly 10 from each adjacent battery cell 14.

The battery cells 14 are arranged in series wherein the firstelectrically conductive tab 16 is electrically connected to the secondelectrically conductive tab 18 of an adjacent battery cell 14.Particularly, the electrically conductive tabs 16, 18 are bentsubstantially at an acute angle to be received on the planar surfaces29, 86 of the support features 26, 82. Each of the support features 26,82 receive the electrically conductive tab 16 of one of the batterycells 14 and the electrically conductive tab 18 of the adjacent batterycell 14 thereon. The support features 26, 82 support and hold theelectrically conductive tabs 16, 18 together during a joining processthereof. It is understood that the electrically conductive tabs 16, 18can be joined by any suitable process such as a welding process and acompression joining process, for example. It is further understood thatthe electrically conductive tabs 16, 18 may be formed in a desired shapeto facilitate establishing the electrical connections therebetween.Additionally, the support features 26, 82 protect the battery assembly10 from damage which may occur during the joining process such asshielding the battery assembly 10 from weld spatter or a laser beamsignal that penetrates through both electrically conductive tabs 16, 18,for example.

To assemble the battery assembly 10, the end frames 11, the coolingmodules 12 having the frame 40 and the cooling assembly 72 coupledthereto are positioned in the stacked relation. One of the battery cells14 is disposed between one of the end frames 11 and the adjacent coolingmodule 12 and between successive cooling modules 12. The tension rods 32of the compression assembly are then inserted in the apertures 31, 46 ofthe ears 30, 44 and coupled to the battery assembly 10 to apply thecompressive force thereto.

In the stacked relation, each of the planar surfaces 29, 86 of thesupport features 26, 82 receive the electrically conductive tab 16 ofone of the battery cells 14 and the electrically conductive tab 18 ofthe adjacent battery cell 14 thereon. The tabs 16, 18 are positioned andheld together by the compressive force applied by the compressionassembly on the battery assembly 10. Supported by the support features26, 82, the tabs 16, 18 are then mechanically and electrically connectedby the joining process, resulting in the battery cells 14 beingelectrically connected in series.

Referring now to FIG. 3, an alternative embodiment of the batteryassembly 10 illustrated in FIGS. 1-2 is shown. The battery assembly 100includes a plurality of end frames 111, a plurality of cooling modules112, a plurality of spacer frames 113, and a plurality ofseries-interconnected battery cells 114 having a first electricallyconductive tab 116 and a second electrically conductive tab 118extending outwardly therefrom. It is understood that the battery cells114 can be any battery cells as desired such as lithium-ion batterycells, nickel-metal hydride battery cells, or other battery cellsemploying a different structure and electrochemistry, for example.

Although each of the end frames 111 has a generally rectangular shape,it is understood that the end frames 111 can have any shape as desired.The end frames 111 can be formed as a unitary frame by injection moldingan electrically non-conductive material such as a nylon, polypropylene,metal, or other material having suitable physical and chemicalproperties, for example. It is understood that the end frame 111 can beformed by any suitable forming process as desired. The end frameincludes an exterior first side (not shown) and an interior second side119. The first side may have a generally planar surface or may includeany surface features as desired. Wall sections 120 are formed on thesecond side 119 of the end frame 111. The wall sections 120 and aninterior surface 123 form a cavity for receiving one of the batterycells 114 therein. The wall sections 120 are designed to engage an outerperimeter 121 of the battery cell 114 and locate the battery cell 114 inmating contact with the interior surface 123. When the end frame 111 isplaced in a stacked relation with the cooling modules 112, the spacerframes 113, and the battery cells 114, the wall sections 120 of the endframe 111 abut an adjacent cooling module 112 or an adjacent spacerframe 113. A recess 124 is formed in a peripheral edge of the end frame111 to receive one of the electrically conductive tabs 116, 118 of thebattery cell 114 therein. The recess 124 of the end frame 111 receivesthe electrically conductive tab 116 therein.

A support feature 125 is formed on a portion 126 of the end frame 111.In the embodiment shown, the support feature 125 has a generallyinverted L-shaped cross-section with a first planar surface (not shown)and a second planar surface (not shown). The first planar surface issubstantially parallel to a longitudinal axis B of the battery assembly100. The second planar surface is adjacent the first planar surface andis substantially perpendicular to the longitudinal axis B. In anon-limiting example, the planar surfaces have a length of about 55 mmand a width of about 7.69 mm. It is understood that the support feature125 can have any shape and size as desired. The support feature 125shown is integrally formed with the end frame 111. It is understood,however, that the support feature 125 can be a separate componentcoupled to the end frame 111 by any suitable means. The support feature125 may include a plurality of ribs 127 shown in FIG. 3 to providestrength and stability to the support feature 125.

Ears 130 are formed adjacent each corner of the end frame 111. Anaperture 131 is formed in each of the ears 130 to receive a tension rod132 of a compression assembly (not shown) therein. The tension rods 132interconnect and align the end frames 111, the cooling modules 112, andthe spacer frames 113 to form the battery assembly 100 and thecompression assembly applies a compressive force to the battery assembly100 to hold the battery assembly 100 in the stacked relation. In thestacked relation, the cooling modules 112, the battery cells 114, andthe spacer frames 113 are arranged in a repeating pattern. The coolingmodules 112 maintain a desired temperature of the battery assembly 100.It is understood that the cooling modules 112 may be of the typedescribed in commonly owned U.S. patent application Ser. No. 12/789,888incorporated herein by reference in its entirety.

As illustrated in FIG. 4, each of the cooling modules 112 includes aframe 140 having an opening 142 formed through a central portionthereof. The frame 140 and the opening 142 have a generally rectangularshape. It is understood that the frame 140 and the opening 142 can haveother shapes to accommodate a shape of the battery cell 114 such assquare, circular, oval, and the like, for example. It is furtherunderstood that the frame 140 may have substantially the same shape asthe end frame 111. The frame 140 can be formed as a unitary frame byinjection molding a material such as a nylon, polypropylene, metal, orother material having suitable physical and chemical properties, forexample. Ears 144 shown in FIG. 3 are formed adjacent each corner of theframe 140. An aperture 146 is formed in each of the ears 144 to receivethe tension rod 132 therein.

Wall sections 160 are formed on a first side 162 and a second side 163of the frame 140. The wall sections 160 facilitate retention one of thebattery cells 114 between the frame 140 and the adjacent spacer frames113 and alignment of the frames 113, 140 in the stacked relation. Whenthe cooling modules 112 are placed in the stacked relation, the wallsections 160 on the first side 162 of the frame 140 abut a second side164 of the adjacent spacer frame 113 and the wall sections 160 on thesecond side 163 of the frame 140 abut a first side 165 of the adjacentspacer frame 113.

In the embodiment shown, a plurality of slots 166 is formed in opposinglegs 168, 170 of the frame 140. The slots 166 provide fluidcommunication through the legs 168, 170 with a cooling assembly 172disposed in the opening 142. The cooling assembly 172, shown in FIG. 4,includes a separator plate 174 interposed between a first thermallyconductive plate 176 and a second thermally conductive plate 178. Asillustrated, the separator plate 174 has a substantially corrugatedshape. It is understood, however, that the separator plate 174 can haveany shape as desired. In a non-limiting example, the entire coolingassembly 172 is disposed in the opening 142. In another non-limitingexample, the thermally conductive plates 176, 178 are affixed to therespective sides 163, 162 of the frame 140 to seal the opening 142 andretain the separator plate 174 therein. It should also be understoodthat the thermally conductive plates 176, 178 can be integrally formedwith the frame 140 by forming the frame 140 around the plates 176, 178employing an injection molding process, for example. The separator plate174 and the thermally conductive plates 176, 178 form a plurality offluid flow channels 180 through an interior of the cooling assembly 172.The flow channels 180 extend between opposing edges of the coolingassembly 172 and are in fluid communication with the slots 166 formed inthe legs 168, 170 of the frame 140.

A support feature 182 is formed on a portion 184 of the frame 140. Inthe embodiment shown in FIG. 4, the support feature 182 has a generallyinverted L-shaped cross-section with a first planar surface 186 and asecond planar surface 188. As illustrated, the first planar surface 186is substantially parallel to the longitudinal axis B of the batteryassembly 100. The second planar surface 188 is adjacent the first planarsurface 186 and is substantially perpendicular to the longitudinal axisB. In a non-limiting example, the planar surfaces 186, 188 have a lengthof about 55 mm and a width of about 7.69 mm. It is understood that thesupport feature 182 can have any shape and size as desired. The supportfeature 182 shown is integrally formed with the frame 140. It isunderstood, however, that the support feature 182 can be a separatecomponent coupled to the frame 140 by any suitable means. The supportfeature 182 may include a plurality of ribs 189 shown in FIG. 3 toprovide strength and stability to the support feature 182.

As illustrated, each of the spacer frames 113 has an opening 190 formedthrough a central portion thereof. The spacer frame 113 and the opening190 have a generally rectangular shape. It is understood that the spacerframe 113 and the opening 190 can have other shapes to accommodate ashape of the battery cell 114 such as square, circular, oval, and thelike, for example. It is further understood that the spacer frame 1113may have substantially the same shape as the end frame 111 or the frame140 of the cooling module 112 if desired. The spacer frame 113 can beformed as a unitary frame by injection molding a material such as anylon, polypropylene, metal, or other material having suitable physicaland chemical properties, for example. Ears 194 shown in FIG. 3 areformed adjacent each corner of the spacer frame 113. An aperture 196 isformed in each of the ears 194 to receive the tension rod 132 therein.

Wall sections 200 are formed on the first side 165 and the second side164 of the spacer frame 113. The wall sections 200 facilitate retentionone of the battery cells 114 between the spacer frame 113 and theadjacent frame 140 of the cooling module 112 and alignment of the frames113, 140 in the stacked relation. When the spacer frames 113 are placedin the stacked relation, the wall sections 200 on the first side 165abut the second side 163 of the adjacent frame 140 and the wall sections200 on the second side 164 abut the first side 162 of the adjacent frame140.

A support feature 202 is formed on a portion 204 of the spacer frame113. In the embodiment shown in FIG. 4, the support feature 202 has agenerally inverted L-shaped cross-section with a first planar surface206 and a second planar surface 208. As shown, the first planar surface206 is substantially parallel to the longitudinal axis B of the batteryassembly 100. The second planar surface 208 is adjacent the first planarsurface 206 and is substantially perpendicular to the longitudinal axisB. In a non-limiting example, the planar surfaces 206, 208 have a lengthof about 55 mm and a width of about 7.69 mm. It is understood that thesupport feature 202 can have any shape and size as desired. The supportfeature 202 shown is integrally formed with the spacer frame 113. It isunderstood, however, that the support feature 202 can be a separatecomponent coupled to the spacer frame 113 by any suitable means. Thesupport feature 202 may include a plurality of ribs 203 shown in FIG. 3to provide strength and stability to the support feature 202.

A connector 210 is affixed to the support features 125, 182, 202. It isunderstood that the connector 210 can be integrally formed with theframes 111, 113, 140 by forming the frames 111, 113, 140 around theconnector 210 employing an injection molding process, for example. Theconnector 210 is at least partially formed from any suitableelectrically conductive material such as a copper material, a copperclad material, or a copper plated material, for example. The connector210 has a generally inverted L-shaped cross-section having a firstportion 212 received on the planar surfaces 186, 206 of the supportfeatures 125, 182, 202 and a second portion 214 received on the planarsurfaces 188, 208 of the support features 125, 182, 202. As shown, thefirst portion 212 having a substantially planar surface 213 issubstantially parallel to the longitudinal axis B of the batteryassembly 100. The second portion 214 is substantially perpendicular tothe longitudinal axis B and includes an inlay element 216 having asubstantially planar surface 218. In the embodiment shown, the inlayelement 216 is at least partially formed from any suitable electricallyconductive material such as an aluminum material, an aluminum cladmaterial, or an aluminum plated material, for example.

In the embodiment shown in FIG. 3, the electrically conductive tabs 116,118 extend outwardly from the perimeter 121 of the battery cell 114. Itis understood that the electrically conductive tabs 116, 118 may extendoutwardly from the battery cell 114 from any location along theperimeter 121 thereof as desired. In the embodiment shown, the firstelectrically conductive tab 116 is formed from an aluminum material, analuminum clad material, or an aluminum plated material. It is understoodthat the first electrically conductive tab 116 can be formed from anyelectrically conductive material as desired. It is further understoodthat the first portion 212 of the connector 210 can be formed from theelectrically conductive material used to form the first electricallyconductive tab 116. The second electrically conductive tab 118 is formedfrom a copper material, a copper clad material, or a copper platedmaterial. It is understood that the second electrically conductive tab118 can be formed from any electrically conductive material as desired.It is further understood that the second portion 214 of the connector210 can be formed from the electrically conductive material used to formthe second electrically conductive tab 118. Each of the battery cells114 is rotated substantially 180 degrees with respect to thelongitudinal axis B of the battery assembly 100 from each adjacentbattery cell 114. As illustrated in FIG. 4, the first electricallyconductive tab 116 extends outwardly into gaps C, F formed between theframe 140, the connector 210, and the adjacent spacer frame 113 or endframe 111. The second electrically conductive tab 118 extends outwardlythrough gaps D, E formed between the frame 140 and the adjacent spacerframe 113 or the end frame 111.

The battery cells 114 are arranged in series wherein the firstelectrically conductive tab 116 is electrically connected to theconnector 210 of the adjacent battery cell 114 and the secondelectrically conductive tab 118 is electrically connected to theconnector 210 of the adjacent battery cell 114. Particularly, the firstelectrically conductive tab 116 is received on the planar surface 218 ofthe inlay element 216. The second electrically conductive tab 118 isbent substantially at an acute angle to be received on the planarsurface 213 of the first portion 212 of the connector 210. The supportfeatures 125, 182, 202 support and hold the connector 210 and theelectrically conductive tabs 116, 118 together during a joining processthereof. It is understood that the electrically conductive tabs 116, 118can be joined by any suitable process such as a welding process and acompression joining process, for example. It is further understood thatthe electrically conductive tabs 116, 118 may be formed in a desiredshape to facilitate establishing the electrical connectionstherebetween. Additionally, the support features 125, 182, 202 protectthe battery assembly 100 from damage which may occur during the joiningprocess such as shielding the battery assembly 100 from weld spatter ora laser beam signal that penetrates through the electrically conductivetabs 116, 118, and the connector 210, for example.

To assemble the battery assembly 100, the end frames 111, the coolingmodules 112 having the frame 140 and the cooling assembly 172 coupledthereto, and the spacer frames 113 are positioned in the stackedrelation. One of the battery cells 114 is disposed between one of theend frames 111 and the adjacent cooling module 112 or spacer frame 113and between one of the spacer frames 113 and the adjacent cooling module112. The tension rods 132 of the compression assembly are then insertedin the apertures 131, 146, 196 of the ears 130, 144, 194 and coupled tothe battery assembly 100 to apply a compressive force thereto.

In the stacked relation, the planar surface 213 of the connector 210affixed to the support features 125, 182, 202 receives the electricallyconductive tab 118 of one of the battery cells 114. The electricallyconductive tab 116 of the adjacent battery cell 114 is received on theplanar surface 218 of the inlay element 216 of the connector 210. Thetabs 116, 118 are positioned and held in contact with the connector 210by the support features 125, 182, 202 and the compressive force appliedby the compression assembly on the battery assembly 100. Supported bythe support features 125, 182, 202, the tabs 116, 118 are thenmechanically and electrically connected to the connector 210 by thejoining process, resulting in the battery cells 114 being electricallyconnected in series.

While certain representative embodiments and details have been shown forpurposes of illustrating the invention, it will be apparent to thoseskilled in the art that various changes may be made without departingfrom the scope of the disclosure, which is further described in thefollowing appended claims.

1. A battery assembly, comprising: a plurality of battery cells having afirst electrically conductive tab and a second electrically conductivetab formed thereon; and a frame disposed adjacent the battery cells instacked relation, the frame including a support feature formed thereon,wherein the support feature supports one of the tabs of at least one ofthe battery cells.
 2. The battery assembly according to claim 1, whereineach of the battery cells is rotated with respect to each adjacentbattery cell.
 3. The battery assembly according to claim 1, wherein thetabs extend outwardly from a perimeter of each of the battery cells. 4.The battery assembly according to claim 1, wherein the support featureincludes at least one substantially planar surface for receiving the oneof the tabs of the at least one of the battery cells thereon.
 5. Thebattery assembly according to claim 1, wherein the support featurereceives the first electrically conductive tab of one of the batterycells and the second electrically conductive tab of another one of thebattery cells thereon.
 6. The battery assembly according to claim 1,further comprising a connector at least partially received on thesupport feature.
 7. The battery assembly according to claim 6, whereinthe connector abuts and is joined with the one of the tabs of the atleast one of the battery cells.
 8. The battery assembly according toclaim 6, wherein the connector includes an inlay element for abuttingand joining with the one of the tabs of the at least one of the batterycells.
 9. The battery assembly according to claim 6, wherein theconnector includes a portion for abutting and joining with the firstelectrically conductive tab of one of the battery cells and an inlayelement for abutting and joining with the second electrically conductivetab of another one of the battery cells.
 10. The battery assemblyaccording to claim 1, wherein the frame is one of an end frame, a spacerframe, and a frame of a cooling module.
 11. A battery assembly,comprising: a plurality of battery cells having a first electricallyconductive tab and a second electrically conductive tab formed thereon,wherein each of the battery cells is rotated with respect to an adjacentbattery cell; and a frame disposed adjacent the battery cells in stackedrelation, the frame including a support feature formed thereon, whereinthe support feature supports the first electrically conductive tab ofone of the battery cells and the second electrically conductive tab ofthe adjacent battery cell.
 12. The battery assembly according to claim11, wherein the first electrically conductive tab and the secondelectrically conductive tab extend outwardly from a perimeter of each ofthe battery cells.
 13. The battery assembly according to claim 11,wherein the support feature includes at least one substantially planarsurface for receiving the first electrically conductive tab of the oneof the battery cells and the second electrically conductive tab of theadjacent battery cell thereon.
 14. The battery assembly according toclaim 11, further comprising a connector at least partially received onthe support feature, wherein a first portion of the connector abuts andis joined with the first electrically conductive tab of the one of thebattery cells and a second portion of the connector abuts and is joinedwith the second electrically conductive tab of the adjacent batterycell.
 15. The battery assembly according to claim 14, wherein the firstportion of the connector and the first electrically conductive tab ofthe battery cells are formed from a substantially similar material. 16.The battery assembly according to claim 14, wherein the connectorfurther comprises an inlay element disposed in the second portionthereof.
 17. The battery assembly according to claim 16, wherein theinlay element of the connector abuts and is joined with the secondelectrically conductive tab of the battery cells.
 18. The batteryassembly according to claim 16, wherein the inlay element of theconnector and the second electrically conductive tab of the batterycells are formed from a substantially similar material.
 19. A batteryassembly, comprising: a plurality of battery cells having a firstelectrically conductive tab and a second electrically conductive tabextending outwardly from a perimeter thereof, wherein each of thebattery cells is rotated with respect to an adjacent battery cell; and aframe disposed adjacent the battery cells in stacked relation, the frameincluding a support feature formed thereon, wherein the support featuresupports the first electrically conductive tab of one of the batterycells and the second electrically conductive tab of the adjacent batterycell during a joining process thereof, and wherein the battery cells areseries-interconnected.
 20. The battery assembly according to claim 19,further comprising connector at least partially received on the supportfeature, wherein a first portion of the connector abuts and is joinedwith the first electrically conductive tab of the one of the batterycells and an inlay element disposed in a second portion of the connectorabuts and is joined with the second electrically conductive tab of theadjacent battery cell.